Product Watch: Toppan’s BOPP-based GL-SP barrier films

Team WhatPackaging? (WP): What materials are used to manufacture your BOPP barrier films, and how do they contribute to sustainability?
Team Toppan: We manufacture our BOPP barrier films using polypropylene (PP) resin combined with specialised barrier resins. These films are developed through a combination of advanced technologies, including special resin formulations, in-line coating, metallising, and off-line coating processes.

WP?: What role do these films play in the packaging industry?
T: Our specialty BOPP films play a critical role in extending product shelf life, enhancing aesthetics, and delivering essential sealing and barrier properties in multilayer packaging structures. With a strong focus on sustainability, we are now enabling these benefits through mono-material solutions that simplify recycling.

Additionally, we help our customers add value by reducing the number of layers in their packaging, cutting down on virgin material consumption, minimising the need for multiple processing steps, and contributing to lower greenhouse gas (GHG) emissions.

All of these efforts are geared towards building more sustainable, efficient packaging solutions without compromising on performance.

WP?: Are your BOPP barrier films recyclable, and what steps are taken to ensure they can be effectively recycled?
T: Yes, our high-barrier BOPP films are designed to support recyclability. We are actively promoting mono-layer BOPP structures that are compatible with existing recycling streams, making them an ideal choice for brands aiming to meet circular packaging targets.

WP?: Do you use recycled content in your BOPP films? If so, what percentage of the product is made from recycled materials?
AK: We are currently committed to zero-waste manufacturing. All scrap material produced during our BOPP film production is recycled, with some reused directly in our operations and the rest supplied to other manufacturers for various molded products.
For BOPP barrier films, particularly in food contact applications, we currently prioritise the use of materials that ensure compliance with strict food safety standards. At the same time, we are actively exploring ways to safely incorporate recycled content into these applications in the future. Meanwhile, for non-food applications, we are already incorporating recycled materials, tailored specifically to the requirements of each end-use.

We also hold the ISCC certification, enabling us to provide films containing PCR content. We are continuously working to expand our sustainable product lineup, supporting our customers in achieving their sustainability goals.

WP?: What certifications or sustainability standards do your BOPP barrier films meet?
T: We hold comprehensive certifications that demonstrate our commitment to excellence and compliance in BOPP film manufacturing, including ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, ISO 5001, ISO 27001:2022, BRC, GMP, ISCC Plus, NABL-accredited lab, SEDEX, and ECOVADIS.

WP?: What is the expected lifespan of your BOPP barrier films, and how do they perform in terms of storage and transformation?
T: We typically adhere to customer requirements regarding shelf life, which are based on specified storage and handling conditions. These are discussed with each customer to ensure optimal performance. Our products are designed to perform across different seasonal conditions, and our optimized packaging ensures the product’s protection during transportation. 

WP?: Can your BOPP films be easily integrated into existing packaging processes or machinery?
T: Yes, our BOPP films are designed to be compatible with standard packaging equipment, including FFS (form-fill-seal), lamination, and converting lines. They offer excellent machinability, consistent slip properties, and reliable sealing behavior, ensuring smooth integration into most existing setups without requiring significant changes. Additionally, we have developed specialised films, such as heat-resistant and higher heat-resistant BOPP films, which can replace polyester films and run seamlessly on final packaging machines.

WP?: Can you provide data or case studies showing the environmental benefits of using your BOPP barrier films in comparison to traditional packaging materials?
T: We have several success stories demonstrating the environmental benefits of our BOPP barrier films. For example, we worked with a brand packaging noodles in a traditional PET with a white CPP structure. PET is challenging to recycle, so we replaced it with our HROB solution, which provided superior barrier properties while being 100% recyclable as a mono-material. This not only enhanced the product’s sustainability but also ensured compatibility with high-speed packaging infrastructure.

WP? Do you have any take-back or recycling programs in place for used BOPP barrier films?
T: We currently operate a dedicated setup equipped with a mechanical recycling facility that converts post-consumer waste into granules, which are then supplied to molding application manufacturers. We plan to expand such facilities in the future. While there are no specific programs in place at this time for BOPP barrier films, we continue to explore opportunities to extend these initiatives into that area as well.